N101-058 TITLE: Application of Coatings for Complex Ship Structural Surfaces Using Electrostatics

TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: PMS 500, DDG 1000 Program, ACAT 1

OBJECTIVE: Develop and demonstrate an approach and the associated technology(ies) usable with a range of surface coating systems that will allow for the application of a uniform coating thickness to complex surfaces using electrostatics.

DESCRIPTION: Coating failures tend to occur most rapidly in areas of geometrical irregularity on corners and edges. While the Navy has invested in edge retentive coating systems, application procedures still require the application of multiple coats (primer, stripe coat on edges and corners, and a topcoat) due to the challenges inherent in coating complex surfaces. The current naval practice requires the application of multiple coats (or in some cases a single thick coat) with extensive quality assurance checks and coating touchup in thin areas to ensure that there are no exposed areas that would be susceptible to corrosion. The need for multiple touchup applications to ensure adequate coverage directly translates to increased labor and materials costs. Many of the areas that need remedial coating application are in the areas of geometric irregularity.

This topic seeks the development of an approach to reliably deposit a uniform coating at a controlled thickness on complex surfaces using electrostatics. The reliable application of a uniform coating could eliminate the need for substantive additional applications of paint to the complex areas that are difficult to reach using conventional coating processes. This would directly translate to an appreciable saving in labor costs. Areas of particular challenge are in tanks and voids where stiffeners, piping, and supports create areas that are nearly inaccessible to conventional coating spray equipment. Electrostatics would take advantage of the steel substrate of the coating application to promote adherence to complex shapes and to areas that are out of the line of sight, such as behind I-beams. The specific electrostatic method chosen must be compatible with the existing range of surface coating systems. For the purposes of demonstrating concept feasibility, initial developmental emphasis should be upon coating systems (primarily epoxies) currently in use in the naval shipbuilding industry such as those qualified to MIL-PRF-23236. The proposed process must be operable in an industrial shipyard environment and must be portable to allow for operation in remote ship spaces by no more than two people.

PHASE I: Demonstrate the feasibility of the application of a uniform coating thickness to complex structures using electrostatics. Establish performance goals and metrics to analyze the feasibility of the proposed solution. Provide a Phase II development approach and schedule that contains discrete milestones for product/prototype development

PHASE II: Develop a prototype of the proposed Phase I concept(s). Using laboratory characterization experiments, validate the performance goals identified in Phase I. Provide manpower, cost-savings and performance metrics. Prepare an implementation and test plan that contains discrete milestones for product development for the purposes of obtaining necessary certifications for shipyard and/or manufacturing sector implementation.

PHASE III: Utilizing the concept(s) developed during Phase I and Phase II, work with Navy and industry to approve and certify the proposed concept for use in Navy applications and then transition this technology to existing and future surface combatant systems.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: This technology would have a broad range of applications in commercial industries such as manufacturing, automobile, construction (infrastructure applications, bridges, etc.) and commercial shipbuilding.

REFERENCES:
1. Kaznoff, A.I. and Brinkerhoff, B., "The Future of Marine Tank Coatings-A U.S. Navy Perspective", Journal of Protective Coatings & Linings, Vol. 22, No. 2, Feb 2005, pg 40-44.

2. MIL-PRF-23236C, Performance Specification, Coating Systems For Ship Structures, Aug 2003. http://assist.daps.dla.mil/online/start/

KEYWORDS: coating; structures; application; automation; corrosion control

** TOPIC AUTHOR (TPOC) **

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